Die structure and method of making same



Dec. 23, 1958 H, F PHlLLlPs 2,865,235

DIE STRUCTURE AND METHOD OF MAKING SAME Original Filed Oct. 21, 1952 PIE-E 1215A mw' Z@ Mk Dit?. SRUCTURE AND METHD MAKING SAME Henry F. Phillips, tairlaud, Calif., assigner' to The Flo- Seai Corporation, Seattle, Wash., a corporation ot Detaware Continuation of appiieation Serial No. 315,396, ctoher 2l, 1952. This application March il, i954, Serial No. 4l3,115

3 Claims. (Ci. 7o-NW This invention is a continuation of application Serial No. 315,896, led October 2l, 1952, and relates to means for Forming pouring spout structure in a blank or blanks of cardboard from which cartons are formed so that the inished carton will have a pouring spout.

One of the objects of the invention is the provision of means for forming uniformly accurate spout structure in carton blanks so that the blanks, when folded to form cartons, with certain parts thereof secured together, the pouring spout structure in such carton will operate satisfactorily.

Heretofore many attempts have been made to make cartons with pouring spouts. inasmuch as a successful pouring spout in cartons also requires a closure for ciosthe pouring opening when the spout is inoperative, it is necessary to employ at least two lapping layers of the cardboard from which the carton is formed in order to both provide a spout and a closure, and the structure on both layers must very accurately cooperate or the spout and closure will not operate satisfactorily.

in the forming of a carton having four sides, which is the most common type of carton, it is customary to form a row of four spaced parallel folding creases or scores on the blank so as to have an extension on the blank outwardly of one of the end folding creases that wi'l be in lapping relation to the side wall that is formed by the end portion of the blank outwardly of the end crease at the otherV end of the row. By making this extension wide enough itA will be adequate to form the layer in which one portion of the pouring spout is formed, and the said side wall lapped by said extension will term the other iayer. Thus no material modification is necessary in the fold" n and gluing of a blank to form a carton having inning spout structure. lt is essential, however, that the spout structures on the lapping layers be uniform in size, sh pe, position,` etc., since any slight changes would rein an inoperative spout in the finished carton.

making of cartons, it has een the V'ce to make a die for the desired carton. This die f is formed of ilat coplanar pieces of wood having ired outlines for holding cutting and creasing rules tween the adjacent edges of different adiacent pieces. rules project from the upper side of the die that is "o med and the blank to be cut and creased is positioned me upwardly projecting edges of the rules. Upon pressing the blank against said edges by conventional means, the blank is cut along lines where it engages the of the cutting rules and it is creased where engagement with the creasing rules. Rules may also be incorporated in the die for scoring and for perforating.

rthe above structure for making cartons has been the l. al one attempted in forming pouring spouts in cartons. l'that is; the box makers have attempted to cut and to ht small pieces` of wood together for holding the desired rules the diethat is to form the carton, so that the spout structure would be formed at the saine time as the carton. The `result an intricate lmalized` assembly ice of rules and blocks or Wooden pieces at places in the die where the spout structure is to be formed.

Dies, generally, for use in cutting and forming boX n';s in which the blocks or pieces between rules are "ui/ved to a base or in which the rules are connected to s 'ch blocks by screws, have been suggested, but such structure is not economically practical, nor possible in snout forming structure since there would be no accessibility to screws in the small pieces that are required for holding the rules that form the spout, and furthermore, any structure in which the spout forming rules are held by separate and separable pieces would not overcome the difficulties heretofore encountered, since vthe pieces may become loosened and strains and tensions on the pieces are not equal.

ln practice, dies, as above described, whether wood or metal pieces are employed, are not satisfactory for forming spout structure. Gradually the rules change their precise relationship to each other that is essential in the forming of registering spout elements, and before a commercially satisfactory run can be accomplished the spout structure will not function.

Practical economy has dictated the use of carton forming dies along conventional lines, and such spout structures that have heretofore been proposed have been Vabandoned because the spout forming elements made along said lines are not satisfactory.

`With the present invention, the formation of such spout structure has been made possible and commercially satisfactory without a material increase in the cost o-f making the cartons, and without modifying the usual manner of making the cartons and of making the main carton forming die.

Other objects and advantages will appear in the description and in the drawings.

.in the drawings,

Fig. 1 is a plan View of one element device.

Fig. 2 is a plan View of another of the elements of a spout forming device.

Fig. 3 is an edge or elevational view of the device of Fig. 2 as seen from the near or lower edge of the device as seen in Fig. 2.

Fig. 4 is a sectional View taken along line 4-4l of Fig. 1.

Fig. 5 is a sectional View taken along line 5 5 of Fig. 1.

Fig. 6 is a reduced size plan view of a conventional carton forming die having the devices of Fig. l and Fig. 2 incorporated therein.

Fig. 7 is a fragmentary sectional View taken along liv e 5?7 of Fig. 6.

Fig. 8 is a reduced size plan View of the device of Fig. Z illustrating (in connection with the device of Fig. 2) the usual means employed in blank cutting devices for freeing the blank from the cutters after a cutting operation.

Fig. 9 is an edge view of the device of Fig. 8 with a blank supported thereon in a position for being cut by the device.

Fig. 10 is a reduced size elevational view showing the spout structure adapted to be formed by the devices of Figs. 1, 2 in a finished carton cut by the means shown in Fig. 6.

it is to be understood that the drawings and the invention, as hereinafter explained in detail, are not to be considered as being restrictive to forming the speci'lic spout that is so explained. The spout hereinafter described is merely illustrative of the invention. Different spout structures would have different arrangements of the cutting and creasing rules, and the spout structure could be formed in layers of sheet material to be seof spout forming cured to a carton wall. It may also be added that in cartons where a pouring opening is in one layer and a closure in another, It is many times quite important that exact registration between structural features be maintained, and under such circumstances, the present invention could be employed.

In detail, referring to Fig. 6 it is customary in the cutting and creasing or scoring of blanks for cartons, to provide a die having cutting rules 1 and creasing rules 2 that are supported vertically (but horizontally extending) in the desired relationship within a wooden frame 3 by blocks 4 of wood. The frame itself may be blocks held together in any suitable manner, and the blocks 4 are fitted together in much the same manner as a jigsaw puzzle with the cutting and creasing rules held tightly between adjacent blocks and which rules space said adjacent blocks the thickness of the rules.

In Fig. 6 rules 1, 2 are arranged so that the space 5 dened by rules 1, 2 at one end of the die will form the outer layer 6 (Fig. 10) of a sealing ap that will lap and be secured to an inner layer 7, and which inner layer will have the shape of the space 8 that is between rules 1, 2 at the other end of the die. These two lapping flaps will form one end of one of two opposed side Walls of the carton when they are glued together.

The outline of space 9 defined by rules 2 in the center of the die will provide the other of two opposed side walls, and spaces 10, 11 defined by rules 2 at opposite sides of space 9 correspond in outline to that of the two remaining sides of the carton, the latter being a four sided carton in the present instance. Rules 1, 2 along the upper and lower edges of spaces 5, 8, 9, and 1.1 that define the outline of spaces l2 to 19, and 191 inelusive. will form the top and bottom closure aps for the carton.

As already stated, the die, as described, for forming a carton blank is conventional and such die is quickly and easily fabricated inasmuch as the flaps, side and end walls are usually relatively large and rectangular, and the wooden blocks used to support the rules are easily made and fitted, and will securely hold the rules in place. It is, of course, understood that the die is supported on a Hat bed so that the necessary pressure on a sheet of cardboard overlying the substantially coplanar and upwardly projecting edges of the rules will not dislodge nor move the rules in direction away from such pressure. The bed will support the rules and the other elements of the die.

The usual and obvious method that has heretofore been attempted in dies where spout and closure structure is desired, has been to support cutting and creasing rules 1n the same manner as rules 1, 2, namely: by forming the rules to the desired shape and then forming separate blocks to hold the rules in place. Such structure has been unsatisfactory for the reason that the spout cutting and' creasing rules gradually shift relative to each other and to the creasing and cutting rules that form the carton blank so that the spout elements formed on one portion of the blank will be out of register with the spout elements formed on another portion that is in lapping relatron to the first mentioned portion.

The obstacles to the conventional method of forming spout structure in carton blanks has been Overcome by providing devices of the general character shown in Figs. l to 5. These are illustrative of devices for forming one spout structure and closure. Obviously a closure and spout structure or pouring opening of another shape and character would have the rules differently arranged.

In Fig. l cutting rule is arranged to define part of the outline of a portion of theV blank that is to ccnstltute a generally V-shaped pouring spout, and a slot cutting rule 2l is positioned'to` form slots along the apex of the V to facilitate'bending.thejmaterial of said spout along said slots. Rule 22 is a'cr'easin'grule and denes the folding crease in the blank along which the spout is secured to the portion 7 (Fig. 10) of said blank, while cutting rule 23 functions with rule 20 to cut out a part 212. (Fig. 10) of the blank that is at one end of the spout portion so that the latter will be free from the material of the blank when the spout is pulled or drawn through an opening in the outer layer 6 of the blank. Rule 25 (Fig. 1) is also a creasing rule, one function of which is to shrink or to draw the part 26 of the spout away from the surrounding material so as to facilitate the ultimate forming of the spout.

Each of the rules 20, 21, 22, 23, 25 may be formed with one or more openings 28 (Fig. 4). The rules, when formed, as seen in the drawings are held in the relationship shown and are partially imbedded in molten metal or other suitable material 27 to the level shown in Figs. 4, 5 or molten metalor other suitable material is poured into a form around the rules while the latter are securely held in their desired relationship, after which the molten material solidics, thus rigidly holding the rules against any possible shifting or movement relative to each other.

The body 27 is preferably rectangular and of the same thickness as the blocks 4 and frame 3. Also, b ody 27 is preferably of a width that will permit it to be posi-v ticned between the rules of the main die for the blankV at the point where it is to be positioned. and said rules also preferably extend completely through the body 27 so that their edges that are opposite the cutting and creasing edges, will be tirmly supported on the bed that supports the die. Thus the downward force against the cutting and creasing edges of the rules will be directly transmitted through the rules to the bed.

Figs. 2 and 3 show the device for forming the closure for the pouring spout, and to which closure the spout formed by the device of Fig. l is glued. This device has cutting rules 29 and a slotting rule 30 and, as seen in Fig. l0, they function to form a generally triangular piece 3l with the row of slots 32 (formed by slotting rule 30) being along the line about which said piece 1s adapted to swing.

Rules 29. 30 are each provided with openings 33 (Fig. 3) that correspond with openings 26 in the rules held in body Z7, and which openings are for the same purpose. Rules 29. 30 are rigidly held in a body 34 that is preferably rectangular and that is of a width suitable for positioning between the die rules where desired. The material of body 34 is the same as that of body 27 and it is formed in the same way.

it should be noted that each of the rules in body 27 and body 34 is preferably formed with one or more openings corresponding to openings 28 and 33.

It is important to note that the rules in bodies 27, 34 are of tempered steel that will retain effective cutting and creasing edges for a relatively long run of blank material. Therefore, the metal of bodies 27. 34 must be of a relatively low melting point or a melting point that is below the temperature at which the temper of the steel rules would be impaired. Also this metal should retain its tight holding engagement with the rules when it cools. An example of a suitable metal would be an alloy of 23% antimony and the remainder of lead. which has a melting point of approximately 500 F. and a melting point preferably not greater than 600 F. Qther alloys can. of course, be used, provided the meltmg point 1s sufficiently low.

Fig. 6 shows the body 27 and the bo-dy 34, which may be called inserts, positioned at opposite ends of the carton forming die. and they are so positioned that when 'the carton blank is formed. thev will form the snout and closure structures in the end sealing flaps 6. 7 that in turn form one of the walls of the carton when the latter is set up and the flaps are secured together as shown in Fi l0.

is seen in Fig. l0 it is vital to the successful operation vof the spout structure formed by the device of Fig. 1 and assente.

the closuregstructure formed by the device oi `Eig. 2 be in precise and accurate registration when the "iiaps'v or layers 6, 7 are secured together. A slight shitting of any of 4the rules` of the insert of Figs. 1 or. 2 would result in the spout being incapable of being readily withdrawn through the opening that is normally closed, by the closure 31.

The accurate positioning of the rules in the bodles 27, 34 is easily accomplished and positively insures against shifting of the rules relative to each other, since the material of bodies 27, 34 iiows around the rules when cooled,l the rules are as firmly held rigid as it the rules and bodies were integrally united.

The inserts of Figs. 1, 2 may be very accurately positioned relative to each other, by shims 35 (Fig. 6) at any one or more of the sides of each insert, and once the inserts are rigidly held in the die they will remain fixed relative to the cutting and creasing rules of the die for the life of the latter.

As seen in Figs. 8, 9 yieldable elements 36 of rubber or the like may be positioned along the cutting and slotting rules of the inserts to ll the blank from the rules after each blank is cut. rTheir use is common in cutting dies, hence they are not shown in Fig 6.

The use of the term cutting rules is intended to cover lany rules that may cut the material of the blanks, whether by making full or partial Cuts or by slotting, and the term creasing rules is intended to cover rules that form lines of weakness along which the blank may be folded.

With the present invention the compete blank forming die can be set up almost as quickly with the inserts for the spout and closure structures as Without them.

There are no screws, small loose pieces or the like in the spout and closure forming inserts. All the operator needs to do is to see that the inserts are so positioned and held that proper registration between the closure and spout is eiiected when the cut blanks go through the folding and gluing process.

When a blank forming die is dismantled, the inserts remain assembled tor use in outer blank f-rming dies without dismantling the insert. As already emphasized, many diiierent types of spout structures can be formed by die inserts having the same general structure as that of the irrerts hereinabove described in detail.

Sin e the inserts are relatively small, there is no noticeable change in their size due to temperature variations.

inasmuch as the melting point of the metal that holds each of the insert dies for forming the spout structure is below the temperature at which the steel rules are impaired, it is, of course, possible to melt the blocks 27, f

34 and to remove or to replace the rules without impairing the temper of the rules that are in the blocks when the latter are melted. This is quite desirable where changes in the sizes of the blocks may be desired, or where it may be desirable to remove the rules for any reason. it is also important, in;ofar as the bodies 27, 34 are crncerned, or the bodies that may carry intrcately formed rules or assemblages of any kind, that these bodies should not chip, crack or become distorted under hard usage on long runs. The fact that there is no shrinkage of the metal away from the rules is quite important.

While the present invention specifically mentions spout forming rules, there may be instances where an insert could be very advantageously u.ed to support rules for cutting and creasing, r either, for carton structure that may be employed on closure flaps or elsewhere at points where registration is essential in a nlshed carton, and which inserts would come within the scope of this invention.

I claim: g

l. The method of making a die for forming, in one operation, a carton blank that is foldable to provide a carton having a pair of lapping, engaged, different flaps provided with a pairrof cut and creased registerable, spout portions cooperative for movement together relative to the remainders of said flaps when the latter are in said lapping engaged relation comprising the steps of; casting a pair of separate blocks about a pair of groups of creasing and cutting rules each group of which is adapted to form a different one of said spout portions, for rigidly holding the rules of each group in each block as a unit with each block and against movement of said rules in each group relative to each other, then releasably supporting separate carton cutting and creasing rules rigid relative to each other solely by tight frictional engagement between said carton cutting and creasing rules and separate blocks that include said pair of blocks with said separate carton cutting and creasing rules being so supported by said separate blocks in positions for cutting and creasing said carton blank including said iiaps and with said separate groups being supported by the blocks carrying them in positions for cutting and creasing said portions in said flaps simultaneously with the cutting and creasing by said carton cutting and creasing rules.

2. The method of making a iiat-bed die that is adapted to form, in one operation of the die, a carton blank including a pair of separate iiaps foldable to lapping engaging relation upon folding said blank to form a carton and also including a pair of portions respectveiy in said separate iiaps adapted for coactive movement relative to each other upon folding said aps to said lapping relation, said method comprising the steps of; arranging a tirst group of cutting and creasing rules in positions relative to each other for forming one portion ot' said pair thereof, arranging a second group of cutting and creasing rules for forming the other portion of said pair thereof, holding the cutting rules in each group in their said positions to support them for movement of each group as a unit separate from the other by casting a separate block of material about and between the rules in each of said groups, releasably supporting the carton and cutting rules for forming said carton blank rigid relative to each other in positions for forming said blank by positioning a plurality of blocks including the cast blocks having said groups held therein in iirm, frictional, but releasable engagement with said carton cutting and creasing rules.

3. The method of making a hat-bed die for forming, in one operation of the die, a carton blank including a pair of separate flaps foldable to lapping relation upon folding said blank to form a carton and also including a pair of portions respectively in said separate tiaps adapted for coactiva movement upon folding said flaps to said lapping relation, said method comprising the steps of; positioning a plurality of separate carton cutting and creasing rules including two sets of liap cutting and creasing rules in positions relative to each other for forming said blank and said iiaps, positioning a plurality of other cutting and creasing rules in two separate groups in positions in said groups for forming said portions respectively, casting a block abo-ut and between sa`d other cutting and creasing rules in each group of said pair thereof in firm engagement with the rules in each group to hold the rules in each group together against movement relative to each other and for handling each group as a unit, releasably holding said cast blocks stationary by and within said sets of flap cutting and creasing rules respectively and in positions within each set for the forming of said portions by said groups of cutting and creasing rules in said blank at the same time said carton cutting and creasing rules and said sets of cutting and creasing rules from said carton and said iiaps, and postioning other blocks in stationary, iirm, but releasable, relationship to said carton cutting and creasing rules and to said sets of flap cutting and creasing rules for holding them against movement relative to each other in directions laterally of the cutting and creasing rules.

(References on following page) Refereuces Cited in the file of this patent UNITED STATES PATENTS Wells Ian. f7, 1896 Boyce Aug. 5, 1902 5 Adsit Oct. '7, 1930 MNaught Sept. 29, 1931 

